NC Program Code Optimization for Faster Machine Tool Cycles
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Solution Overview
Problem
Machining programs generated by CAD/CAM devices often include redundant NC program codes and inefficient processing sequences, leading to slow machine tool operations and longer cycle times, particularly when created by operators unfamiliar with machining programs.
Innovation Solution
An optimization device that analyzes preparatory and auxiliary function codes within machining programs, optimizes them by deleting unnecessary codes, integrating blocks, rearranging block orders, and optimizing coordinate values, and replacing fixed cycle codes with interpolation codes, to generate an optimized program that reduces processing time and cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If machining programs are generated with emphasis on reliable operation by CAD/CAM device or operator, then operation reliability is improved, but processing time increases and cycle time becomes longer
Solution Approach 1:
The numerical controller performs preliminary analysis of preparatory function codes and auxiliary function codes in each block before execution, identifying redundant codes and optimization opportunities. This preliminary action allows the system to optimize code sequences and eliminate unnecessary operations in advance, achieving both reliability through thorough analysis and improved processing speed through optimized execution.
2Reliability
If redundant NC program codes and unnecessary G codes/M codes are included in machining programs, then operation reliability is improved, but processing time increases and cycle time becomes longer
Solution Approach 1:
The numerical controller extracts and identifies redundant preparatory function codes and auxiliary function codes from the machining program blocks. By analyzing code sequences and determining which codes are unnecessary for the actual machining operations, the system removes these redundant elements, thereby reducing cycle time while maintaining operational reliability through the extracted essential codes.
Solution Approach 2:
The system discards redundant and unnecessary NC program codes identified through block analysis, while recovering and retaining only the essential codes needed for reliable operation. This selective discarding and recovering process eliminates time-wasting redundant operations while preserving the necessary code sequence for reliable machining execution.
3Ease of operation
If machining programs are created by operator unfamiliar with machining programs, then ease of operation is improved, but program efficiency deteriorates with duplication of codes and incorrect sequences
Solution Approach 1:
The numerical controller provides feedback by analyzing the machining program blocks and identifying inefficiencies such as code duplication and incorrect sequences. This automated analysis feedback compensates for the operator's lack of expertise, detecting and correcting program efficiency issues that would otherwise be difficult for unfamiliar operators to identify, thereby maintaining both ease of operation and program efficiency.
Solution Approach 2:
The numerical controller performs self-service by automatically analyzing and optimizing the machining programs it receives. Instead of relying on operator expertise to create efficient programs, the system independently identifies redundant codes, corrects sequence errors, and optimizes code sequences, thereby compensating for operator inexperience and maintaining high program efficiency while preserving ease of operation.
Data Source
AI summary
To optimize NC program cores included in a generated machining program and expedite operation of a machine tool. An optimization device includes a block analysis unit, a code processing unit, and a program generation unit. The block analysis unit analyzes a preparatory function code and/or an auxiliary function code for each of a plurality of blocks included in a first program. The code processing unit performs a process on the preparatory function code and/or the auxiliary function code in a plurality of successive blocks based on a result of the analysis by the block analysis unit and optimizes the first program. The program generation unit generates the first program optimized by the code processing unit as a second program.